Upon receiving a Customer Purchase Order for a new product, the Customer Service Representative (CSR) e-mails the VP-Quality & Engineering a copy of the PO, quoting documents, specifications, and other items of note. The CSR creates the first article part number in the M2M Item Master per TOP-ORDER.

The Forging Engineer (assigned to the customer) begins the FAI process by determining the requirements for the FAI. Once determined, the known quality information is forwarded to the QA Manager. The QA Manager begins the process of creating the Quality Plan. The Quality Plan must be approved by the Forging Engineer. The Forging Engineer creates the FAI BOM, Router and Spec ID from the newly created first article part. These must be approved by the QA Manager.

Quality Planning

The Quality Manager creates a Quality Plan using the customer purchase order, Customer Print, and typically information that comes from the new die hatch meeting. The QA Manager then coordinates all quality related activities required to produce parts that satisfy the customer's requirements. During the review of the first article, the standard BOM, Router, and Customer Specifications are reviewed. All pertinent and special information such as inspection instructions, gages, and any inspection forms needed are added to BOM, Router, Spec ID system and sent to the Forging Engineerfor review and approval.

Anyone becoming aware of the need to add or modify a Quality Plan is to notify the QA Manager.

First Article Inspection

When a First Article Inspection is required the Quality Plan can specify the CMM Programmer/Operator's or QC Inspector's measuring equipment.TOP-MSURE. The CMM Programmer/Operator or QC Inspector's records the results of the inspection on the inspection record document as assigned by the Quality Plan.

For dimensional evaluation: The CMM Programmer/Operator or QC Inspector provides documentation of the inspection to the QC Supervisor for approval. The QC Supervisor reviews the inspection. The QC Supervisor tben sends the part and the documentation to the QA Manager initialing and dating approval or rejection.

When the QA Manager receives nonconforming first article(s), he/she reviews the information to verify the nonconformity, ensures that the process variables which caused the nonconformity has either been corrected or stopped, ensures that all nonconforming parts have been properly handled per TOP-NOCON.

When the QA Manager receives conforming first article(s), the Quality Plan is reviewed for completeness and the QA step is scanned off signaling for shipments to commence. Shipping Supervisor or Shipping Leadman must be notified as to the location of the parts.

First Article Inspection Buy off

It is the responsibility of the QA Manager to arrange for source inspection, when required, and follow thru till first article is approved and documented in the company files.